Carbon Fiber Wave Spring Forming for Corrosion and Fatigue Resistance
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Solution Overview
Problem
Conventional wave springs made from metal are prone to corrosion and fatigue, which limits their durability and reliability in various applications.
Innovation Solution
A carbon fiber wave spring is created by winding a unidirectional carbon fiber prepreg sheet around a mandrel, cutting it into a disc-shaped ring, forming it into a desired wave shape, and curing it to produce a durable and fatigue-resistant wave spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal wave springs are used, then they provide good elasticity and load-bearing capacity, but they are subject to corrosion and fatigue
Solution Approach 1:
The patent applies composite materials by using carbon fiber reinforced polymer (CFRP) instead of traditional metal materials. The carbon fiber provides high strength and fatigue resistance, while the polymer matrix provides corrosion resistance and flexibility, creating a composite wave spring that overcomes the limitations of metal materials.
Solution Approach 2:
The patent changes the material parameters by transitioning from metallic materials to carbon fiber composite materials. This fundamental material parameter change enables the wave spring to achieve both high reliability (corrosion and fatigue resistance) and acceptable manufacturability through the described fabrication process.
2Reliability
If carbon fiber prepreg is wound and cured to form wave spring, then corrosion and fatigue resistance is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-impregnating the carbon fiber bundles with polymer resin to create prepreg material before winding. This preliminary impregnation ensures proper material distribution and bonding, simplifying the subsequent winding and curing processes while maintaining high product quality and reliability.
Solution Approach 2:
The patent uses an intermediary mandrel during the winding process to maintain the cylindrical shape and provide a template for the carbon fiber prepreg. The mandrel acts as a temporary support structure that enables precise winding and is removed after curing, facilitating the manufacturing process despite its temporary complexity.
3Strength
If unidirectional carbon fiber prepreg sheet is wound around mandrel, then structural integrity and fatigue resistance are improved, but manufacturing time and process complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-impregnating carbon fiber bundles with resin to create ready-to-use prepreg material. This preliminary preparation allows for rapid winding and curing operations, reducing overall manufacturing cycle time while ensuring consistent structural integrity and fatigue resistance in the final product.
Solution Approach 2:
The patent replaces traditional mechanical fastening or metal bonding methods with a chemical curing process. The polymer resin cures to bond the carbon fiber layers together, creating a strong, integrated structure that eliminates the need for additional mechanical assembly steps, thereby reducing manufacturing time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The carbon fiber wave spring offers enhanced resistance to corrosion and fatigue, providing improved durability and reliability compared to traditional metal wave springs.
Implementation Method 1
curing the disc-shaped ring in the wave shape to form a wave spring
Data Source
AI summary
A method of making a carbon fiber wave spring includes forming a disc-shaped ring from prepreg carbon fibers. The disc-shaped ring is then formed into a desired wave shape. The disc-shaped ring in the wave shape is then cured to form a wave spring.